Rigid paper container



Oct. 29, 1963 A. REINSBERG 3,108,730

RIGID PAPER CONTAINER v Filed May 28, 1962 1;; j fa f2 ,f4 1,6 f8 l :"5

| 4 20 I l l l Q f22/ l l /F 22 J l l l l y l l l l Doug X ,gq i A I |ll l 5ba/'0% Igan/7. V l 'Lc f/f f l' i i D l i V 2 I l I v 2 --v i e30S/l 22 .Icare .Daal/r 16 12v V M 2 /7 .fra/'e 505/* [52 l 20 f7ff7 521gkm United States Patent Oilice 3-,if8,730 Patented 9ct. 29, 19633,103,730 RGID PAPER CNTAINER Adolph Heinsberg, 375 S. Canon Drive,Beverly Hills, Calif. Filed May 28, 1962, Ser. No. 198,160 2 Claims.(Cl. 229-7) The present invention relates to rigid paper cartons orcontainers of .the general type presently used by the dairy industry forpackaging milk. However, the improved paper Carton of the invention, aswill become evident as the description proceeds, is suitable forpackaging a wide variety yof materials, either liquid or granular, whichmay be poured from a pouring aperture formed at the top corner of thecarton.

The present invention is particularly concerned With the rigid-type ofcarton, or container, which is preferably `formed of stii paper, coatedwith polyethylene to make it Water proof; the container being used Iforthe packaging of fluids, such as milk.

Rigid paper cartons for liquids, -especially for the packaging Ianddispensing of milk, are in widespread use and Ldemand at the prese-nttime. It 'has been the practice lin the past to provide a wax coatingfor these cartons to -rnake them leak proof. However, recently the Waxcoatings are being replaced to -a large extent by polyethylene coatingsWhich do not have the tendency to ake or leak, as was the tendency ofthe -waX coated cartons. Although the present invention is not limitedto the polyethylene type of coated carton, the application of theconcepts of ythe invention to that type of ycarton is presentlypreferred.

There are, in general, three types of rigid paper cartons in present-daywidespread use by the dairy industry. However, each of these prior arttypes is subject to certain inherent limitations and `disadvantageswhich the rigid paper container, or carton, of the present inventionseeks to overcome.

Prob-ably one of the most troublesome problems 'surrounding the use ofrigid paper cartons by the dairy industry is that of the shipment of theready made empty cartons in some instances, or of the unformed cartonsin other instances, to the dairies to be lled with liquid milk, or to beformed and filled with milk.

The aforementioned ready made type of prior art rigid paper carton isshipped to the dairy in its fully set-up three-dimensional form, so thatall that is required at the dairy is to lill the cartons with milk.However, the use of such a cart-on involves excessively highrequirements in shipping space, and corresponding high shipping costs,for the shipment of the empty cartons from the manufacturer to thedairies. Also, because of the lack of warehousing facilities at mostdairies, the tremendous space requirements of the empty cartons of thisparticular prior art type requires that they be shipped to the dairieson a daily and complicated delivery schedule. It is apparent that thedairies cannot economically Warehouse such set-up three-dimensionalempty cartons on the premises until and as they are needed.

In an attempt to overcome the ditculties mentioned in the precedingparagraph, the aforementioned unfonned type of carton has been devisedin the prior art. This latter type of carton may be shipped at, in ablank or two-dimensional form. This, of course, solves to a large extentthe problem of excessive requirements and costs in shipping andWarehousing space. However the use of this latter type of prior artcartonhas created its own problems. One of these problems is that theusual prior art carton of this latter type requires complicatedmachinery at the dairies to set up the cartons into theirthree-dimension form in which they are in condition to be filled withmilk.

Therefore, to set up the latter type .of prior art cartons,

the ldairy must rent or buy appropriate machinery, which in itself isrelatively complicated and expensive, and which involves the requirementof different machines for the different sizes of carton. These machines,as noted, are complicated and expensive, and they additionally requireskilled persons to operate and maintain them. Thus, instead of coniiningits operation to the processing and sale of milk, the dairy is compelledin effect also to enter the paper carton manufacturing business.

The above factors place a burden -on t-he dairy industry, and thisburden adds to the strain of meeting rigid time schedules for thedelivery of their milk, especially in the event that any of the machineshappen to break down. It is apparent, therefore, that the entire'operation required to set up the second type of prior art carton underconsideration'represents a troublesome, unwanted and relatively highcapital expenditure on the part `of the dairies.

An important `object of the present invention is to provide an improvedrigid paper type of container which is completely fabricated prior toshipment to the dairies, and yet which can be shipped in a flattenedcondition so as to reduce shipping charges to a minimum and to permitthe containers to be Warehoused in a reasonable space until needed.

Another object is to provide such an improved rigid paper container orcarton which is capable of being set up and -lled at the dairy by meansof a simple loperation and Without the requirement -for skilledpersonnel or complicated machinery.

Yet another object is to provide such an improved rigid paper containerwhich has a llat top formed ush with the upper edges of the sides of thecontainer. rather than being recessed as is the case in some prior artcontainers of this general type.

The flush construction of t'he top of the container of the embodiment ofthe invention to be described obviates any tendency for dirt or spilleduid to collect on the top surface and become contaminated. The ilat topof the carton of this embodiment of the present invention is alsoadvantageous in that it permits the cartons to be conveniently stackedon top of one another, thereby to conserve refrigerator space in thedairy and distribution centers when 'the carton is filled, stored andmarketed.

Another object yof the invention is to provide such an improved cartonwhich requires less paper than the prior art cartons of the same generalsize, which is simple to construct, and which can be manufactured at arelatively low cost to be so-ld at a relatively low price.

A feature of the invention is the provision of such an improved rigidpaper container Which has an improved pouring aperture formed in thecorner of its top member, the aperture being surroundedby a cover memberwhich is shaped to limit the ilow of the liquid therethrough so as toprevent surges and spilling of the liquid, especially when the containeri-s full.

The above-described cover is configured to overlap the pouring edge ofthe aperture so as to protect the edge from ingers or other unsanitaryhandling. In addition, the cover is capable of being pressed shut whenthe carton is not inuse to keep odors or the like from the milk.Moreover,..the cover is formed to be flush with the top of the carton sothat no recessed area is presented thereby for the collection of dirtand uid.

Another feature of the invention is the provision of a closable aperturein the bottom of the carton which permits the .pouring aperture at thetop to be sealed shut at the carton manufacturing facility. This bottomaperture enables the carton to be iilled upside down, and when thecarton is so filled, the bottom aperture is closed and sealed by meansof a simple operation, as will be described.

Certain features of the rigid paper carton to be described have beenpreviously described in -my patent application Serial No. 555,011, tiledDecember 23, 1955, now abandoned.

The improved rigid paper container of the present invention ispreferably formed of polyethylene coated rigid paper, as mentionedabove. The carton of the illustrated embodiment of the invention, aswill be described, is formed of three pieces. These pieces include a topmember, a bottom member, and a barrel member which is formed into thesides of the container.

As mentioned above, the improved rigid paper container of the presentinvention is completely formed at the factory and prior to shipment tothe various dairies. The container of the invention is constructed to beappropriately scored so that it may be pressed at into anaccordion-pleated shape for shipping purposes.

As noted, the top pouring aperture of the container of the embodiment ofthe invention to be described is sealed shut when the carton is shipped.However, the bottom iilling aperture is open, so that the iiattenedcontainer may be quickly set up into its three-dimensional form, and incondition for filling. rlIhis three-dimensional set-up is achieved, forexample, by introducing va shot of air pressure through the open bottomfilling aperture. The air pressure may be, for example, of the order of25 pounds per square inch, such pressures being readily available atmost dairies. The air pressure line, of course, should contain lters orother means to assure that clean and sanitary air only will enter thecarton.

The introduction of -air pressure into the carton of the inventioncauses it immediately to assume its three-dimensional set up permanentshape. While a carton is still upside down, the liquid is introducedinto lthe carton through the aperture in the bottom until the carton isfull. The aperture is then sealed closed by a simple application of heatand pressi-ng together, for example, vwhen the car- -ton is formed ofpolyethylene coated paper.

rIhe features of the invention `which vare believed to be new are setlforth in the claims. The invention itself, however, may :best beunderstood by a consideration of the following description, `when takenin conjunction with the accompanying drawing, in which:

FIGURE `l is a developed view, on -a reduced scale, of the 4barrelmember -which forms the side walls of the con- Itainer of the embodimentlto be described;

FIGURE 2 is an end view of the barrel member of FIGURE l, taken alongthe line 2 2 of FIGURE 1;

FIGURE 3 is a top plan view of a top member for the container of theembodiment to be described;

FIGURE 4 is a bottom view of a bottom member for the container of theembodiment to be described;

FIGURE 5 is a perspective view, on a reduced scale, of the container ofthe embodiment to be described, illustrated in its set-upthree-dimensional form;

FIGURE 6 is a fragmentary sectional view of the container, ltaken alongthe line 6 6 of FIGURE 5, and illustrating the manner in which the topmember is sealed to the rupper edges of the side walls;

FIGURE 7 is a fragmentary sectional view of the container, taken alongthe line 7-7 of FIGURE 5, `and illustnating the manner in which thebottom member is sealed to the lower edges of the side Walls;

FIGURE 8 is au end view of the container of FIGURE 5, when the containeris in its ilattened two-dimensional configuration, with its side wallsin a folded accordionpleated condition;

FIGURE 9 is a fragmentary perspective View of the container invertedwith its bottom side up, illustrating the manner in which the containeris formed into its threedimensional :set-up configuration by theintroduction of air pressure, and how liquid is thereafter introducedinto the container;

FIGURE 10 is a bottom view of the bottom member of the container,illustrating ythe manner in which a corner d aperture is sea-led afterthe container has been til-led with huid, such as millt, or othermaterial; and

FIGURE ll iliustrates the manner in which the pouring spout at the topof 4the container may be opened to permit the Huid in the container tobe poured out.

As illustrated in FIGURE 1, the container of the embodiment to bedescribed includes a barrel member 10. The barrel member may, forexample, be formed of rigid paper. ri`he paper is preferably coated witha suitable plastic, such as polyethylene, to render the containerleakproof and water-tight.

The barrel member 1d of FIGURE 1 has a rectangular coniiguration, asshown, and it is scored along the dotted lines A, B, C and D to permitthe barrel member to be folded so that it can form four side walls forthe container. These side walls are designated `12, 14, 16 and 18.

When the barrel member 10 is formed into the configuration of FIGURE 5,it has a solid rectangular shape. The upper edges of the side walls liesubstantially in a first common plane, `and the lower edges of the sidewalls lie in a second common place spaced from and parallel to the firstplane.

The side walls 14 and '1S are scored, as represented by the dotted linesE and F so as to permit the receptacle to be flattened, as Awill -bedescribed, with the side walls 14 and 118 bent inwardly along thescorelines E and F.

rihe container of the present invention, in the embodiment illustratedherein, includes a top -mem-ber Z0 (FIG- URE 3) which, like the barrelmember 10, is formed of la stiff paper which may be treated with aplastic coating, such as polyethylene. The top member 2,0 |has a squareconfiguration, and it includes integral aps 22.

The top member 2Q is vattached to the barrel member 10 at the upperedges of the side walls in the manner shown in FIGURES 5 land 6. The topmember 20' is positioned on the upper edges of the -side walls fwith theaps 22 overlying the edges, as shown in FIGURES 5 and 6. The top member2d may be sealed to the barrel mem-ber 10, when the plastic-coated paperis used by the simple application of heat and a slight pressing action.

It will be appreciated that the top member 20 is sealed to the barrelmember -10 in ya position to lie in the common plane of the top edges ofthe side walls and flush with these edges. The at, flush configurationof the top member permits other like containers to be stacked over thecontainer of the invention, and also precludes any possibility of fluidor dirt ,gathering at the top of the container with the resultingcontaminating action.k

A pouring spout or aperture is provided at one cor-ner of the top member20, and this aperture is covered by a cover 3b. The cover 3G is formedintegral with the top y member 20, and it includes a pair of iiaps whichextend outwardly, as best shown in FIGURE 3. When the top member 2d ismounted on the barrel member 10, and sealed thereto as shown in FIGURE5, the cover 30 is folded down over the corresponding cornerk of theside Walls 14 and V16, and its two naps are folded over one another toform an enclosing structure.v This structure is best shown, for example,in FIGURE 5.

In order that the cover 30 of the pouring spout will not be too tightlybonded when it is sealed shut, and in order that lthe cover may beopened to the position shown in FIGURE l1 without destructive tearing,the ink forming the advertising message on the carton can be continuedup to extend under part of the area covered by the cover 30.

The cover member 30 may be sealed to the closed con dition of 'FIGURE 5by the application of heat, and a slight pressure, when the material ofthe receptacle 1s plastic-coated, as suggested above.

It will be Vappreciated that slits are formed in the cover member 30, asindicated in FIGURES 3 and 5, to perv -mit the cover member to assumeits illustrated shape, and also to permit the cover member to. beunsealed and M hinged up from its closed position of FIGURE to its openposition of FIGURE 11, so as to permit pouring.

When the cover member 30 is moved down to its closed position of FIGURE5, it completely covers and protects the pouring edge, so that fingersor other contaminating agents cannot normally come in contact with thatedge. It will also be appreciated that when the cover member 30 is inthe closed condition shown in FIGURE 5, its top surface is flush withthe top surface of the top member 20, so that the cover member, like thetop member, does not provide any recessed surface for the accumulationof liquid or dirt.

The assembly of the invention, as illustrated in FIG- URES 4 and 9,includes a bottom member 50. ,This bottom member may also be formed ofplastic-coated paper, and it has a square configuration, as shown inFIGURE 4. 'Ihe bottom member includes a plurality of aps 52. These flapsare folded up from the plane of the bottom 50 and are sealed to thelower edges of the side Walls, as shown in FIGURES 7 and 9. The bottommember 50 is sealed to the barrel member in position such that it isrecessed up from the common plane of the lower edges of the side walls,as Ibest shown in FIGURE 9.

An aperture 6G is formed in the bottom member 5@ at one corner. Thislatter aperture enables the containers of the invention to be set upinto their three-dimensional form at the dairies with ease and facilityby the introduction of a burst of pressurized air, and it also permitsthe liquid to b e introduced into the container, as mentioned above.

The barrel member is scored, as indicated by the dotted lines E and F inFIGURE 1; and the top and bottom members are also scored as indicated bythe dotted lines in FIGURES 3, 4, 5 and 9, so that the container may bepressed to a flattened configuration, as shown in FIGURE 8.

It should be stressed that prior to the above-mentioned iiattening ofthe container, the container is fully formed and the top member andbottom member are sealed thereto, and the cover 30 is sealed down overthe pouring aperture at the top of the container, all these operationsbeing carried out at the manufacturing facility, and prior to shipmentto the dairies.

Then, the container is flattened to the configuration of FIGURE 8 tofacilitate shipment, this flattening being achieved by causing thevarious portions of the container to fold about the corresponding scorelines. The folded container of FIGURE 8 has the ap 60 folded to an opencondition, so that its corresponding lower aperture is open.

When the container arrives at the dairy, it is placed on a suitableconveyor in inverted manner. Then, and as indicated schematically inFIGURE 9, a blast of air pressure is introduced through the fillingaperture 60 in the bottom member 50, and this blast immediately causesthe container to assume its set-np three-dimensional shape. Then, theliquid is filled into the container throughthe same aperture, and theaperture is later sealed closed, as shown in FIGURE 10. This sealedclosure is accomplished by the simple application of heat anda slightpressure.

The invention provides, therefore, an improved contain` er, or carton,of the rigid paper type. As noted above, the improved container of thepresent invention is preferably composed of stiff paper coated with asuitable plastic, such as polyethylene. The container of the inventionis particularly advantageous, in that it can be completely formed at themanufacturing center, and prior to shipment tothe dairies. However, thecontainer of the invention is capable of being shipped flat to thedairies to con- 6 serve shipping and warehousing space. When theflattened containers arrive at the dairies, no particular machinery orskilled personnel are required to set the container up to itsthree-dimensional form. Instead, a simple conveyor and a suitablesource'of air pressure are all that are required. v

Ihe containers of the invention also are advantageous in that they maybe filled with milk or other fluid through the same aperture throughwhich they were inflated, and when the containers are in the originalinverted position. After filling, the lower apertures may be sealed by asimple manual or automatic operation, and the containers are then filledand ready for delivery.

The actual configuration of the improved container of the invention isadvantageous in that the container has a solid rectangular configurationto permit ease of stacking. In addition, the cover and spoutconfiguration are such that there is no ltendency for dirt orothercontaminants to gather at any portion of the container.

While a particular embodiment of the container of the invention has beenshown and described, modifications may be made, and it is intended inthe claims to cover al1 such modifications as fall within the scope ofthe inven tion.

What is claimed is:

1. A paper container including: a barrel member for forming side wallshaving their upper edges lying in substantially a first common plane andhaving lower edges lying in substantially a second common plane spacedfrom and parallel to said first common plane; a top member sealed tosaid barrel member at the upper edges of the side Walls to lie in saidrst common plane ush with said upper edges when the container is set upfor use, and said Itop member having a pouringapert-ure formed in onecorner thereof; a cover for the pouring aperture formed integral withsaid top member as extensions of the side edges of said top member atsaid corner of said barrel member, and said cover having a top.I surfaceflush with the top surface of said top member, said cover being shapedto be pressed closed down over the upper edges of said barrel member atsaid corner thereof so as to cover aperture; a bottom member sealed tosaid barrel member at the lower edges of said side Walls and recessed upfrom said second common plane, said bottom member having an apertureformed at a corner thereof; a flap member on said bottom memberextending around the aperture therein and adapted to be sealed to theinner face of the portion of at least one of said side walls extendingbeyond said bottom member to close the aperture; and two opposing onesof said side walls and said top and bottom member `being scored topermit the container to be folded into a flattened condition With saidopposing side Walls and said top and bottom members having anaccordion-pleated configuration.

2. The paper container of claim 1 in which said barrel member and saidtop and bottom members are formed of rigid paper coated withpolyethylene.

References Cited in the file of this patent UNITED STATES PATENTS2,761,609 Arkin Sept. 4, 1956 2,865,550 Bergstein Dec. 23, 19582,893,295 Magill July 7, 1959 2,896,839 Barnes et al July 28, 19592,904,239 Wilcox Sept. l5, 1959 2,925,949 Locke Feb. 23, 1960 3,082,926Powell Mar. 26, 1963

1. A PAPER CONTAINER INCLUDING: A BARREL MEMBER FOR FORMING SIDE WALLSHAVING THEIR UPPER EDGES LYING IN SUBSTANTIALLY A FIRST COMMON PLANE ANDHAVING LOWER EDGES LYING IN SUBSTANTIALLY A SECOND COMMON PLANE SPACEDFROM AND PARALLEL TO SAID FIRST COMMON PLATE; A TOP MEMBER SEALED TOSAID BARREL MEMBER AT THE UPPER EDGES OF THE SIDE WALLS TO LIE IN SAIDFIRST COMMON PLANE FLUSH WITH SAID UPPER EDGES WHEN THE CONTAINER IS SETUP FOR USE, AND SAID TOP MEMBER HAVING A POURING APERTURE FORMED IN ONECORNER THEREOF; A COVER FOR THE POURING APERTURE FORMED INTEGRAL WITHSAID TOP MEMBER AS EXTENSIONS OF THE SIDE EDGES OF SAID TOP MEMBER ATSAID CORNER OF SAID BARREL MEMBER, AND SAID COVER HAVING A TOP SURFACEFLUSH WITH THE TOP SURFACE OF SAID TOP MEMBER, SAID COVER BEING SHAPEDTO BE PRESSED CLOSED DOWN OVER THE UPPER EDGES OF SAID BARREL MEMBER ATSAID CORNER THEREOF SO AS TO COVER APERTURE; A BOTTOM MEMBER SEALED TOSAID BARREL MEMBER AT THE LOWER EDGES OF SAID SIDE WALLS AND RECESSED UPFROM SAID SECOND COMMON PLANE, SAID BOTTOM MEMBER HAVING AN APERTUREFORMED AT A CORNER THEREOF; A FLAP MEMBER ON SAID BOTTOM MEMBEREXTENDING AROUND THE APERTURE THEREIN AND ADAPTED TO BE SEALED TO THEINNER FACE OF THE PORTION OF AT LEAST ONE OF SAID SIDE WALLS EXTENDINGBEYOND SAID BOTTOM MEMBER TO CLOSE THE APERTURE; AND TWO OPPOSING ONESOF SAID SIDE WALLS AND SAID TOP AND BOTTOM MEMBER BEING SCORED TO PERMITTHE CONTAINER TO BE FOLDED INTO A FLATTENED CONDITION WITH SAID OPPOSINGSIDE WALLS AND SAID TOP AND BOTTOM MEMBERS HAVING AN ACCORDION-PLATEDCONFIGURATION.